Apparel and Sporting Equipment with an UV Radiation Curable Material and Method of Manufacturing Thereof

ABSTRACT

An article of apparel or sporting equipment, such as garments and footwear incorporates a molded component formed of a UV radiation curable material. In the case of an article of footwear, the UV radiation curable material may be formed into an outsole. The method of manufacturing such articles include placing an ultraviolet radiation curable material in contact with a molding surface; conforming the UV radiation curable material to a shape of the molding surface, forming a molded component; and removing the molded component from the molding surface, such that the component maintains the shape of the molding surface. The molded component may be exposed to ultraviolet radiation in an amount and for a duration that is sufficient to partially cure or fully cure the UV radiation curable material.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims priority to,co-pending U.S. Patent Application entitled “Apparel and SportingEquipment with an UV Radiation Curable Material and Method ofManufacturing Thereof,” filed on Apr. 23, 2018, and assigned applicationSer. No. 15/959,550, which claims priority to U.S. ProvisionalApplication entitled “Apparel and Sporting Equipment with an UVRadiation Curable Material and Method of Manufacturing Thereof,” filedon Apr. 24, 2017, and assigned application No. 62/488,978, both of whichare incorporated herein by reference in their entireties.

FIELD

This disclosure relates generally to articles of apparel or sportingequipment, such as garments and footwear that comprise a componentformed from an ultraviolet (UV) radiation curable material.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

Conventional articles of footwear normally include both an upper andsole structure. The upper generally forms an interior void that securelyand comfortably receives a foot. The sole structure may be secured tothe upper and is generally positioned between the foot and the ground.This sole structure may attenuate ground reaction forces, providetraction, as well as limit potentially harmful foot motion. Accordingly,the upper and sole structure operate together to provide a comfortablestructure that is well suited for use in a wide variety of activities.

The sole structure may comprise multiple layers that are conventionallyreferred to as an insole, a midsole, and an outsole. The insole is athin, compressible member located within the void of the upper andadjacent to the midsole and the foot in order to enhance comfort. Themidsole may be secured to the upper and forms a middle layer in the solestructure that attenuates the ground reaction forces. The outsole formsthe element of the sole structure that makes contact with the ground andis usually fashioned from a durable and wear-resistant elastomericmaterial that may include a tread pattern to impart traction.

Despite the various models and characteristics available withconventional footwear, new footwear models and constructions arecontinually desired to provide further development and advancement inthe art.

DRAWINGS

In order that the disclosure may be well understood, there will now bedescribed various forms thereof, given by way of example, referencebeing made to the accompanying drawings, in which:

FIG. 1A is a flow chart of a method of manufacturing a component of anarticle of apparel or sporting equipment according to the teachings ofthe present disclosure;

FIG. 1B is a flow chart of optional steps associated with the method ofFIG. 1A;

FIG. 1C is a flow chart of other optional steps associated with themethod of FIG. 1A;

FIG. 2A is a cross-sectional schematic view of an article of apparel orsporting equipment formed according to the teachings of the presentdisclosure;

FIG. 2B is a schematic view of an article of apparel or sportingequipment formed according to the teachings of the present disclosure;

FIG. 2C is a perspective schematic view of an article of footwear formedaccording to the teachings of the present disclosure;

FIG. 2D is a schematic view of the bottom of the article of footwear ofFIG. 2C;

FIG. 3A is a flow chart of a method of forming an article of footwearusing the component formed in the process of FIG. 1;

FIG. 3B is a flow chart of optional steps associated with the method ofFIG. 3A;

FIG. 3C is a flow chart of other optional steps associated with themethod of FIG. 3A;

FIG. 4A is a flow chart of another method of forming an article offootwear using the component formed according to the teachings of thepresent disclosure;

FIG. 4B is a flow chart of optional steps associated with the method ofFIG. 4A; and

FIG. 5 is a schematic representation of a method of finishing an articleaccording to the teachings of the present disclosure.

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

The present disclosure generally provides a method of forming an articleof apparel or sporting equipment, such as a garment or footwear, as wellas the article that is formed. Ultraviolet (UV) radiation curablematerials can be used to form a durable portion of an article of apparelor sporting equipment, such as a portion of an interior or exteriorsurface of the article. For example, shaped portions of UV radiationcurable elastomers can be molded or shaped using relatively lowtemperatures and pressures, and optionally cured, without exposing thetextile to the high temperatures and pressures which would be requiredto shape and cure conventional rubber in a vulcanization process.

The method includes placing an UV radiation curable material in contactwith a molding surface; using heat or pressure or both to conform the UVradiation curable material to a shape of the molding surface, thereby,forming a molded component; and removing the molded component from themolding surface, such that the component maintains the shape of themolding surface. Optionally, the method may further comprise forming theUV radiation curable material into a sheet prior to having the materialconform to the shape of the molding surface, cutting or trimming the UVradiation curable material before the conforming step and/or from themolded component.

The molded component may be exposed to ultraviolet radiation in anamount and for a duration that is sufficient to at least partially curethe UV radiation curable material. In some examples, the moldedcomponent may be exposed to UV radiation in an amount and for a durationthat is sufficient to fully cure the UV radiation curable material. TheUV radiation curable material may comprise an UV radiation curableelastomer, one or more photoinitiators, and optionally, one or moreprocessing aids.

According to another aspect of the present disclosure, a method offorming an article of footwear is provided. This method comprisesreceiving an upper; receiving a component of an article formed accordingto the molding process previously described above and further definedherein; and attaching the upper to the component. In other words, themethod comprises attaching an upper to a component, wherein thecomponent is an article formed according to the molding processpreviously described above and as further defined herein. The componentmay be an outsole formed from a UV radiation curable material. Themethod may further comprise attaching a midsole or midsole component tothe outsole before or concurrently with attaching the upper to theoutsole. The step of attaching the outsole to either the midsole or theupper may include exposing the outsole to the UV radiation in an amountand for a duration that is sufficient to either partially cure or fullycure the UV radiation curable material. When desirable, other means ofattaching the upper and the component, or of enhancing the bond strengthbetween the upper and the component may be used, such as using anadhesive or primer, as well as providing a surface texture to theoutsole, midsole, or upper prior to the attaching.

The method may further comprise providing a pattern, such as a treadpattern, to at least one surface of the outsole. Other traction elementsmay also be attached to the outsole. When desirable, a cooling step maybe included as part of the method after the application of a compressiveforce (e.g., pressure or vacuum) and optional heat, and prior toremoving the outsole from the mold.

According to another aspect of the present disclosure, an article offootwear is provided. The article of footwear comprises an upper and anoutsole having a shape, such as a predetermined shape. The outsolecomprises the UV radiation curable material in an uncured or partiallycured state. The outsole is attached to the upper. Optionally, thearticle of footwear may also comprise a midsole or a midsole componentattached to the outsole. The outsole may include at least one surfacewith a tread pattern, where the tread pattern is present in a portion ofthe outsole comprising the UV radiation curable material, where the UVradiation curable material is in an uncured, partially cured, or fullycured state. When desirable, an adhesive or primer applied to theoutsole, midsole, and/or upper may be used to form the bond orattachment between the components, or to enhance the strength of thebond or attachment between the components. In some examples, theattachment between the components is maintained after exposure up to aforce of 2.5 kgf/cm measured according to a Bond Strength TestingProtocol as described below.

According to yet another aspect of the present disclosure, a method offinishing an article of footwear having an upper, an outsole, andoptionally, a midsole comprising an article of footwear with an outsoleformed from an uncured or partially cured UV radiation curable materialis provided. This method comprises providing the article of footwear andexposing the outsole to ultraviolet (UV) radiation, such that the UVradiation curable portion of the outsole is fully cured.

Further areas of applicability will become apparent from the descriptionprovided herein. It should be understood that the description andspecific examples are intended for purposes of illustration only and arenot intended to limit the scope of the present disclosure.

The following description is merely exemplary in nature and is in no wayintended to limit the present disclosure or its application or uses. Forexample, the molded component comprising an ultraviolet (UV) curablematerial made and used according to the teachings contained herein isdescribed throughout the present disclosure in conjunction with footwearin order to more fully illustrate the composition and the use thereof.The incorporation and use of such a molded UV radiation curablecomponent in other applications, including apparel such as garments,sporting equipment, or the like are contemplated to be within the scopeof the present disclosure. It should be understood that throughout thedescription, corresponding reference numerals indicate like orcorresponding parts and features.

The present disclosure generally provides a method of forming acomponent of an article of apparel or sporting equipment. Referring toFIG. 1A, this method 10 comprises placing an ultraviolet (UV) radiationcurable material in contact with a molding surface 20, conforming the UVradiation curable material to the shape of the molding surface, thereby,forming a molded component 30, and removing the molded component fromthe molding surface 40. When desirable, the use of heat and/or pressureapplied to the UV radiation curable material may assist the material toconform to the shape of the molding surface. The molded component thatis removed from the molding surface 40 is able to maintain the shape ofthe molding surface.

Referring now to FIG. 1B, when temperature is applied to at least aportion of the UV radiation curable material, the temperature may beincreased before the placing of the material in contact with the moldingsurface, as well as prior to or during conforming the material to theshape of the molding surface 23. The heat applied to the UV radiationcurable material is generally maintained between about ambient or roomtemperature and less than 170° C. Alternatively, the temperature mayrange between about 40° C. and about 165° C. The UV radiation curablematerial softens with this predetermined temperature range, such thatthe UV radiation curable material can be contoured or shaped as desiredto conform to the shape of the molding surface. The temperature of theUV radiation curable material is generally reduced to a point whereinthe material is no longer softened prior to the exposing the UVradiation curable material to ultraviolet (UV) radiation.

Still referring to FIG. 1B, a compressive force may be applied to themolding surface or to the UV radiation curable material during theconforming of the material to the shape of the molding surface 27. Thiscompressive force may be applied by increasing pressure or applying avacuum 29. A cooling step may be optionally used after the applicationof the compressive force and prior to removing the molded component fromthe mold. The pressure that is applied to the UV radiation curablematerial is generally between about 2 kgf/cm² (˜28 psi) to about 200kgf/cm² (˜2,800 psi). Alternatively, the amount of pressure appliedranges from about 3 kfg/cm² (˜40 psi) to about 6 kfg/cm² (˜80 psi);alternatively, between about 6 kfg/cm² (˜80 psi) to about 35 kfg/cm²(˜500 psi); and alternatively, between about 35 kfg/cm² (˜500 psi) toabout 150 kfg/cm² (˜2,100 psi).

For the purpose of this disclosure the terms “about” and “substantially”are used herein with respect to measurable values and ranges due toexpected variations known to those skilled in the art (e.g., limitationsand variability in measurements).

For the purpose of this disclosure any range in parameters that isstated herein as being “between [a 1^(st) number] and [a 2^(nd) number]”or “between [a 1^(st) number] to [a 2^(nd) number]” is intended to beinclusive of the recited numbers. In other words the ranges are meant tobe interpreted similarly as to a range that is specified as being “from[a 1^(st) number] to [a 2^(nd) number]”.

When desirable, various precautions or safeguards may be undertaken byone skilled in the art in order to protect at least a portion of the UVradiation curable material from being exposed to UV radiation during oneor more steps of the method. Such precautions or safeguards may include,but not be limited to, masking a portion of the molding surface ormaintaining the UV radiation curable material in an environment that isabsent any UV/visible light.

The molding surface may be a single substantially planar surface orincorporated as part of a compression mold or a mold used in aninjection molding process or another type of forming process, such ascast molding, thermoforming or vacuum forming. The molding surface maybe entirely or at least partially smooth or textured. The texturing ofthe molding surface may be done in a manner that provides the surface ofthe molded component with a greater degree of roughness or the formationof irregularities that will enhance the ability to bond a surface ofanother material or component thereto. This bonding or adherence may beaccomplished with or without the use of an adhesive or cement. Thetexturing of the molding surface may also be done in order to impart avisible design or pattern to the surface of the molded component.

Referring now to FIG. 1C, the method 10 may further comprise forming theUV radiation curable material into a sheet 15 prior to placing thematerial in contact with the molding surface 20. The UV radiationcurable material may also be subjected to cutting or trimming any excessmaterial or unnecessary material prior to forming the material into amolded component 25. Additional UV material may be trimmed or cut fromthe molded component 45 as part of a finishing operation. Otherfinishing operations, which include but are not limited to, polishingembossing, steaming/ironing, brushing, or decorative stitching, to namea few can also be performed on the molded component without exceedingthe scope of the present disclosure.

Referring once again to FIG. 1A, after the molded component is from themolding surface 40, the molded component may be exposed to ultraviolet(UV) radiation 50, in an amount and for duration in time that issufficient to at least partially cure the UV radiation curable material.Alternatively, upon exposure to the UV radiation, the UV radiationcurable material may be fully or substantially cured. For the purpose ofthis disclosure, the term “partially cured” is intended to denote theoccurrence of at least about 1%, alternatively, at least about 5% of thetotal polymerization required to achieve a substantially full cure. Theterm “fully cured” is intended to mean a substantially full cure inwhich the degree of curing is such that the physical properties of theUV radiation curable material do not noticeably change upon furtherexposure to additional UV radiation.

When desirable, UV radiation curable material may alternatively beexposed to the UV radiation 50 when it is still in contact with themolding surface 30, i.e., prior to being removed from the moldingsurface 40. In this case, the cutting or trimming of the moldedcomponent 45 may be performed after exposure to the UV radiation.

The UV radiation curable material generally comprises one or morephotopolymers or light-activated resins that will undergo across-linking reaction upon exposure to ultraviolet (UV) radiation. TheUV radiation curable material may comprise a mixture of variousmultifunctional monomers, oligomers, and/or low molecular weightpolymers or copolymers, along with one or more photoinitiator(s) thatcan undergo polymerization in the presence of UV radiation. Uponexposure to UV radiation, the photoinitiator decomposes into a reactivespecies that activates polymerization of specific functional groups thatare present in the multifunctional oligomers, monomers, or polymers.

As used herein, the term “polymer” refers to a molecule havingpolymerized units of one or more species of monomer. The term “polymer”is understood to include both homopolymers and copolymers. The term“copolymer” refers to a polymer having polymerized units of two or morespecies of monomers, and is understood to include terpolymers. As usedherein, reference to “a” polymer or other chemical compound refers oneor more molecules of the polymer or chemical compound, rather than beinglimited to a single molecule of the polymer or chemical compound.Furthermore, the one or more molecules may or may not be identical, solong as they fall under the category of the chemical compound. Thus, forexample, “a” polyurethane is interpreted to include one or more polymermolecules of the polyurethane, where the polymer molecules may or maynot be identical (e.g., different molecular weights).

The end result of curing a light-activated resin in this manner is theformation of a thermoset or cross-linked polymer network. Thus the UVradiation curable material may be described as being an UV radiationcurable elastomer. Alternatively, the UV radiation curable material maycomprise an UV radiation curable rubber. The UV radiation curablematerial may comprise one or more thermoset polymers, thermoplasticpolymers, or combinations thereof. When desirable, the one or morethermoplastic polymers may be one or more thermoplastic polyurethanes(TPU).

Several specific examples of various monomers that may be used in the UVradiation curable material include, but are not limited to, styrene andstyrenic compounds, vinyl ethers, N-vinyl carbazoles, lactones, lactams,cyclic ethers, cyclic acetals, and cyclic siloxanes. Several specificexamples of oligomers and low molecular weight polymers or copolymersthat may be incorporated into the UV radiation curable material include,without limitation, epoxides, urethanes, polyethers, or polyesters, eachof which provide specific properties to the resulting material. Each ofthese oligomers or polymers may be functionalized using an acrylate.Alternatively, the UV radiation curable material may include a mixtureof urethane and acrylate oligomers or a copolymer thereof.

Photoinitiation may occur via a free radical mechanism, an ionicmechanism, or a combination thereof. Under an ionic mechanism, thepolymerizable oligomers, monomers, or polymers are doped with eitheranionic or cationic photoinitiators. Several examples of suchphotoinitiators, include without limitation, onium salts, organometalliccompounds, and pyridinium salts. In the free radical mechanism, thephotoinitiators generate free-radicals by the abstraction of a hydrogenatom from a donor or co-initiator compound (i.e., a 2-component system),or by the cleavage of a molecule (i.e., a 1-component system). Severalspecific examples of abstraction type photoinitiators, include but arenot limited to, benzophenone, xanthones, and quinones with common donorcompounds being aliphatic amines. Several specific examples ofcleavage-type photoinitiators include, without limitation, benzoinethers, acetophenones, benzoyl oximes, and acylphosphines. Photocurablematerials that form through the free-radical mechanism undergochain-growth polymerization, which includes three basic steps:initiation, chain propagation, and chain termination. Alternatively, thephotoinitiators are independently selected and may include phosphineoxides, benzophenones, a-hydroxy-alkyl aryl ketones, thioxanthones,anthraquinones, acetophenones, benzoins and benzoin ethers, ketals,imidazoles, phenylglyoxylic acids, peroxides, and sulfur-containingcompounds.

The amount of photoinitiators present in the UV radiation curablematerial is determined by the effective amount necessary to inducecrosslinking of the UV radiation curable material. This amount may rangefrom about 0.05 weight percent (wt. %) to about 5 wt. %, alternatively,from about 0.1 wt. % to about 2 wt. %, and alternatively, from about 0.2wt. % to about 1 wt. % based on the weight of the UV radiation curablematerial. A single type of photoinitiator or a mixture of differentphotoinitiators may be used.

For the purpose of this disclosure, the term “weight” refers to a massvalue, such as having the units of grams, kilograms, and the like.Further, the recitations of numerical ranges by endpoints include theendpoints and all numbers within that numerical range. For example, aconcentration ranging from 40% by weight to 60% by weight includesconcentrations of 40% by weight, 60% by weight, and all concentrationsthere between (e.g., 40.1%, 41%, 45%, 50%, 52.5%, 55%, 59%, etc.).

According to one aspect of the present disclosure, the UV radiationcurable material may comprise, consist of, or consist essentially of amillable polyurethane gum that includes ethylenic unsaturation, one ormore photoinitiators, and at least one additional crosslinking additivethat comprise two or more ethylenically unsaturated groups. The millablepolyurethanes may be prepared by the reaction of a di- or polyisocyanatewith bis(hydroxyl)-functional compounds, at least one of which containsethylenic unsaturation. Alternatively, unsaturated polyester polyols maybe used, alone or in combination with other isocyanate-reactivecomponents, such as polyoxyalkylene glycols and/or diols capable ofproviding pendent ethylenic unsaturation. A commercial example of such aUV radiation curable material is Millathane® UV (TSE Industries Inc.,Clearwater, Fla.). Further description of such a UV radiation curablematerial is provided in U.S. Publication No. 2016/0362552, the entirecontent of which is hereby incorporated by reference.

For the purpose of this disclosure, the terms “at least one” and “one ormore of’ an element are used interchangeably and may have the samemeaning. These terms, which refer to the inclusion of a single elementor a plurality of the elements, may also be represented by the suffix“(s)”at the end of the element. For example, “at least onepolyurethane”, “one or more polyurethanes”, and “polyurethane(s)” may beused interchangeably and are intended to have the same meaning.

The additional crosslinking additive present in the curable polyurethanecomposition may include any low molecular weight compounds that containtwo or more ethylenically unsaturated groups. These unsaturated groupsmay include, without limitation, glycerol diallyl ether, 1,6-hexanedioldi(meth)acrylate, triallylisocyanurate, trimethylolpropanedi(meth)acrylate, trimethylolpropane tri(meth)acrylate, glyceroldi(meth)acrylate, glycerol tri(meth)acrylate, propoxylated glyceroltriacrylate, 1,2-divinyltetramethyldisiloxane, divinylbenzene, and thelike. The molecular weight of this additional crosslinking additive maybe less than about 2000 Da, alternatively less than about 1000 Da,alternatively less than about 500 Da. The concentration of thecrosslinking additive in the UV radiation curable material is selectedbased upon the amount of ethylenic unsaturated groups that are desired.The concentration of this additive may range from about 0.01 wt. % toabout 15 wt. %, alternatively, from about 1 wt. % to about 12 wt. %, andalternatively, from about 5 wt. % to about 10 wt. % based on the overallweight of the UV radiation curable material.

When desirable, the UV radiation curable material may optionallycomprise one or more additional processing aids, including withoutlimitation, plasticizers, mold release agents, lubricants, antioxidants,flame retardants, dyes, pigments, reinforcing and non-reinforcingfillers, fiber reinforcements, and light stabilizers or UV absorbers.When an UV absorber is incorporated into the UV radiation curablematerial in order to enhance the environmental stability thereof, it maybe necessary or desirable to use a more powerful UV light source toachieve full cure of the material, or use an UV light source having anoutput wavelength that is in a range within the UV spectrum at which theUV absorber exhibits a reduced level of absorbance.

The reinforcing fillers that may optionally be incorporated into the UVradiation curable material may be organic, i.e. polymeric, or inorganicin nature. These fillers may exhibit a mean, weight average particlesizes that is ≤1 μm, alternatively, in the range between about 20nanometers (nm) to about 500 nm. Several specific examples ofreinforcing fillers include, but are not limited to, pyrogenic (i.e.,fumed) metal oxides, such as alumina, titania, ceria, silica, and thelike; colloidal metal oxides, such as colloidal alumina or silica;carbon black and acetylene black; metal hydroxides, such as aluminumhydroxide; glass or polymer microspheres; or limestone, talc, clay, andthe like. The amount of filler present in the UV radiation curablematerial is selected based upon the requirements associated with aparticular end use. Typically, the amount of reinforcing filler presentin the UV radiation curable material ranges from 0 wt. % to about 20 wt.% based on the total weight of the UV radiation curable material.Fillers having the same chemical composition may be considered to benon-reinforcing fillers when their mean, weight average particle size isgreater than 1 μm, alternatively, in the range of about 2 mm to about500 mm.

The UV radiation curable material may be cured by irradiation with UVlight transmitting a wavelength that is the same as the excitationwavelength exhibited by the photoinitiator present. The UV light may beproduced from any known source, including without limitation, low,medium, or high pressure mercury vapor lamps, xenon lamps, quartzhalogen lamps, or lasers operating in the short wavelength portion ofthe spectra, e.g., in the range of about 180 nm to about 400 nm. Severalmore specific examples of UV light sources include, but are not limitedto, short-wave UV lamps, gas-discharge lamps, ultraviolet LEDs, UVlasers, tunable vacuum ultraviolet (VUV) obtained from sum anddifference frequency mixing, or plasma and synchrotron sources ofextreme UV radiation.

The duration in time that the UV radiation curable material isirradiated with UV radiation is variable and based upon the nature andtype of reactive oligomers, monomers, or polymers present in the UVradiation curable material, as well as type and concentration of thecrosslinking additives, photoinitiators, and fillers, as well as thetype and power associated with the available UV light source. Theduration of UV exposure may range less than a second to several hours;alternatively, the exposure time is between about 1 second and about 1hour; alternatively, between about 5 seconds and 5 minutes. The UVradiation curable material may be irradiated at ambient or roomtemperature within the confines of a molding operation or at atemperature associated with the component formed in a molding orextrusion process. When desirable the molded part may be subjected to acooling step prior to irradiation with UV light. Although, no thermalcure is necessary, a dual cure system may be used when desirable.

According to another aspect of the present disclosure, the component ofthe article of apparel or sporting equipment may be a garment or anarticle of footwear, such as for example, an outsole. As used herein,the terms “article of footwear” and “footwear” are intended to be usedinterchangeably to refer to the same article. Typically, the term“article of footwear” will be used in a first instance, and the term“footwear” may be subsequently used to refer to the same article forease of readability.

The article of footwear,-apparel, or sporting equipment of the presentdisclosure may be designed for a variety of uses, such as sporting,athletic, military, work-related, recreational, or casual use. Thearticle may be used outdoors on paved or unpaved surfaces (in part or inwhole), such as on a ground surface including one or more of grass,turf, gravel, sand, dirt, clay, mud, and the like, intended for theperformance of an athletic competition or as a general outdoor surface.The article may also be desirably used with indoor activities, such asindoor sports, shopping, and everyday work.

Referring now to FIG. 2A, the article of apparel or sporting equipment80 may comprise a first molded component 85A that includes anultraviolet (UV) radiation cured material; and a second component 90.The first and second components 85A, 90 are attached to each other andform the article of apparel or sporting equipment 80. The first andsecond components 85A, 90 may be attached to each other at least by abond at the interface 95 formed directly between the UV radiation curedmaterial of the first component 85A and the second component 90. Theinterface 95 between the UV radiation cured material of the firstcomponent 85A and the second component 90 is free of adhesive materials.

According to another aspect of the present disclosure, the article ofapparel, or sporting equipment 80 as shown in FIG. 2B may comprise afirst component 85B having a predetermined shape that includes an UVradiation curable material in an uncured or partially cured state, and asecond component 90. The first and second components 85B, 90 areattached to each other and form the article of apparel or sportingequipment 80. An adhesive or primer layer 95B may be located on asurface of the first component 85B or second component 90 that assistsin attaching the two components 85B, 90 together.

Referring now to FIGS. 2C and 2D, when the article of apparel isfootwear 100 or a shoe 100, the article may comprise, consist of, orconsist essentially of an upper 110 and an outsole 120 having apredetermined shape. The outsole 120 is attached to the upper 110. Atleast part of the outsole 120 comprises the UV radiation curablematerial as described above and further defined herein in a cured state,an uncured state, or partially cured state. When desired, a midsole 130or a midsole component 130 may be present, which is attached to theoutsole 120.

Referring now to FIG. 2B, the outsole 120 refers to the very bottom ofthe shoe that is in direct contact with the ground. The outsole 120 maybe relatively smooth 123 or include a tread pattern 125. The outsole mayalso optionally include a plurality of other traction elements 127 thatprovide support or flexibility to the outsole 120 and/or are includedfor other aesthetic design purposes. The traction elements 127 mayinclude, but are not limited to cleats, studs, spikes, or similarelements configured to enhance traction for a wearer during cutting,turning, stopping, accelerating, and backward movement.

Since the outsole 120 is the outer most sole of the shoe, it is directlyexposed to abrasion and wear. Various portions of the outsole 120 may beconstructed with different thickness and exhibit different degrees offlexibility. The materials that comprise the outsole 120 should providesome degree of waterproofing, durability, and possess a coefficient offriction that is high enough to prevent slipping. In some cases two ormore materials of different densities can be incorporated into theoutsole 120 to give a hard wearing outer surface and a softer, moreflexible midsole 130 for greater comfort. The outsole 120 may be asingle layer or may contain multiple layers of the same or similarmaterial.

The outsole 120 may be directly or otherwise operably secured to theupper 110 using any suitable mechanism or method. As used herein, theterms “operably secured to”, such as for an outsole that is operablysecured to an upper, refers collectively to direct connections, indirectconnections, integral formations, and combinations thereof. Forinstance, for an outsole that is operably secured to an upper, theoutsole can be directly connected to the upper (e.g., glued with cementor an adhesive), the outsole can be indirectly connected to the upper(e.g., with an intermediate midsole), can be integrally formed with theupper (e.g., as a unitary component), and combinations thereof. When amidsole is present, the upper 110 may be stitched, glued, or otherwiseattached to the midsole at any suitable location.

Still referring to FIGS. 2C and 2D, the upper 110 of the footwear 100has a body which may be fabricated from materials known in the art formaking articles of footwear, and is configured to receive a user's foot.The upper 110 of a shoe consists of all components of the shoe above theoutsole 120 and midsole 130 when present. The different components ofthe upper 110 may include a toe box, heal counter, and an Achillesnotch, to name a few. These components are attached by stitches ormolded and fused to become a single unit to which the outsole and themidsole are attached.

The upper 110 or components of the upper 110 usually comprise a softbody made up of one or more lightweight materials. The materials used inthe upper 110 provide stability, comfort, and a secure fit. For example,the upper may be made from or include one or more components made fromone or more of natural or synthetic leather, a textile or both. Thetextile may include; a knit, braided, woven, or nonwoven textile made inwhole or in part of a natural fiber; a knit, braided, woven or non-woventextile made in whole or in part of a synthetic polymer, a film of asynthetic polymer, etc.; and combinations thereof. The textile mayinclude one or more natural or synthetic fibers or yarns. The syntheticyarns may comprise, consist of, or consist essentially of thermoplasticpolyurethane (TPU), polyamide (e.g., Nylon®, etc.), polyester (e.g.,polyethylene terephthalate, PET), polyolefin, or a mixture thereof.

The upper 110 and components of the upper 110 may be manufacturedaccording to conventional techniques (e.g., molding, extrusion,thermoforming, stitching, weaving, knitting, etc.). While illustrated inFIG. 2A as a generic design, the upper 110 may alternatively have anydesired aesthetic design, functional design, brand designators, or thelike.

Still referring to FIG. 2C, the upper 110 may further comprise laces 113or other securing or foot engagement structures (e.g., strap, etc.) maybe provided to securely hold the shoe 100 to a wearer's foot. A tonguemember, bootie, or other similar type structure may be provided in ornear the shoe instep area in order to increase comfort and/or tomoderate the pressure or feel applied to the wearer's foot by the laces113.

When desirable, at least a portion of the upper 110 of the article offootwear, and in some embodiments substantially the entirety of theupper, may be formed of a knitted component. The knitted component mayadditionally or alternatively form a component of the upper or anotherelement of the article of footwear 110 such as the midsole 130, forexample. The knitted component may have a first side forming an innersurface of the upper 110 (e.g., facing the void of the article offootwear 100) and a second side forming an outer surface of the upper110. An upper 110 including the knitted component may substantiallysurround the void so as to substantially encompass the foot of a personwhen the article of footwear is in use. The first side and the secondside of the knitted component may exhibit different characteristics(e.g., the first side may provide abrasion resistance and comfort whilethe second side may be relatively rigid and provide water resistance).The knitted component may be formed as an integral one-piece elementduring a knitting process, such as a weft knitting process (e.g., with aflat knitting machine or circular knitting machine), a warp knittingprocess, or any other suitable knitting process. That is, the knittingprocess may substantially form the knit structure of the knittedcomponent without the need for significant post-knitting processes orsteps. Alternatively, two or more portions of the knitted component maybe formed separately and then attached. In some embodiments, the knittedcomponent may be shaped after the knitting process to form and retainthe desired shape of the upper (for example, by using a foot-shapedlast). The shaping process may include attaching the knitted componentto another object (e.g., a strobel) and/or attaching one portion of theknitted component to another portion of the knitted component at a seamby sewing, by using an adhesive, or by another suitable attachmentprocess.

Forming the upper 110 with the knitted component may provide the upper110 with advantageous characteristics including, but not limited to, aparticular degree of elasticity (for example, as expressed in terms ofYoung's modulus), breathability, bendability, strength, moistureabsorption, weight, and abrasion resistance. These characteristics maybe accomplished by selecting a particular single layer or multi-layerknit structure (e.g., a ribbed knit structure, a single jersey knitstructure, or a double jersey knit structure), by varying the size andtension of the knit structure, by using one or more yarns formed of aparticular material (e.g., a polyester material, a monofilamentmaterial, or an elastic material such as spandex), by selecting yarns ofa particular size (e.g., denier), or a combination thereof.

The knitted component may also provide desirable aestheticcharacteristics by incorporating yarns having different colors or othervisual properties arranged in a particular pattern. The yarns and/or theknit structure of the knitted component may be varied at differentlocations such that the knitted component has two or more portions withdifferent properties (e.g., a portion forming the throat area of theupper may be relatively elastic while another portion may be relativelyinelastic). In some embodiments, the knitted component may incorporateone or more materials with properties that change in response to astimulus (e.g., temperature, moisture, electrical current, magneticfield, or light). For example, the knitted component may include yarnsformed of a thermoplastic polymer material (e.g., polyurethanes,polyamides, polyolefins, and nylons) that transitions from a solid stateto a softened or liquid state when subjected to certain temperatures ator above its melting point and then transitions back to the solid statewhen cooled. The thermoplastic polymer material may provide the abilityto heat and then cool a portion of the knitted component to thereby forman area of bonded or continuous material that exhibits certainadvantageous properties including a relatively high degree of rigidity,strength, and water resistance, for example.

In some embodiments, the knitted component may include one or more yarnsor strands that are at least partially inlaid or otherwise insertedwithin the knit structure of the knitted component during or after theknitting process, herein referred to as “tensile strands.” The tensilestrands may be substantially inelastic so as to have a substantiallyfixed length. The tensile strands may extend through a plurality ofcourses of the knitted component or through a passage within the knittedcomponent and may limit the stretch of the knitted component in at leastone direction. For example, the tensile strands may extend approximatelyfrom a biteline of the upper to a throat area of the upper to limit thestretch of the upper in the lateral direction. The tensile strands mayform one or more lace apertures for receiving a lace and/or may extendaround at least a portion of a lace aperture formed in the knitstructure of the knitted component.

Still referring to FIGS. 2C and 2D, the midsole 130, when present aspart of the shoe 100, provides additional stability and disperses thepressure applied by the foot to the ground. In other words, a midsole130 can be used to cushion, as well as provide support and protectionfor the foot. Midsoles 130 are often constructed of a combination ofmaterials. A dual density midsole 130 is one in which the midsole 130 isconstructed of a combination of two materials that have differentdensities. The denser material is usually located where the foot wouldnormally tend to roll. Midsoles 130 may be formed in a molding operationor cut and formed from sheet stock. The midsoles 130 may be formed as asingle unit or from any desired number of independent pieces or partswithout departing from the scope of the present disclosure.

Several specific examples of materials that may be used to form themidsole 130 of a shoe 100 include various types of polymeric foammaterials. These polymeric foam materials include, without limitation,polyurethane (PU), ethylene vinyl acetate (EVA), phylon, Phylite®, andLunar® foams. Phylite®, and Lunar® foams are trademarks of Nike Inc.(Beaverton, Oreg.).

Polyurethane (PU) foam, which is a dense, durable and stable midsolematerial, forms a firm midsole that provides protection from impact.Ethylene vinyl acetate (EVA) foam is soft, light, and flexible. EVA foamis an inexpensive midsole material because it can be cut and shaped fromflat sheets of EVA foam. However, EVA foam also compresses faster thanother midsole materials and may become flat over time as the air trappedwithin the foam is squeezed out. Once the EVA foam becomes compacted, itmay not return to its original shape.

Phylon foam is a very lightweight, low-profile and responsive foammaterial. One example of Phylon foam is made of EVA foam pellets thatare compressed, heat expanded and then cooled in a mold.Compression-molded phylon midsoles can be sculpted into a variety ofdesigns. Phylon foam is easy to identify by the fine wrinkles the foamshows after usage.

Phylite® foam, which is a combination of 60% Phylon and 40% rubber canbe used to form a midsole 130 through the use of various moldingtechniques, such as injection molding. Phylite® foam is lighter thanrubber, but heavier than Phylon® foam and can function as a dual midsolematerial.

Lunar® foam is a hybrid of ethylene vinyl acetate (EVA) foam and nitrilerubber. It is 30% lighter than regular compression molded EVA foam orPhylon® foam. Instead of absorbing the impact when your heel strikes thefloor it distributes the pressure along the foam to give a more evenimpact across the foot. Lunar® foam may be used in conjunction with orsurrounded by either Phylon® foam or Phylite® foam as a carrier. WhenLunar® foam is placed in a Phylon® carrier it may sometimes be referredto as Lunarlon® midsole. When the Lunar® Foam is placed in a Phylite®carrier it may sometimes be referred to as Lunarlite® midsole.

The midsole component 130 may be at least partially made from foammaterials having a density that is less than about 0.25 g/cm³;alternatively, less than about 0.2 g/cm³; alternatively, within therange of about 0.075 to about 0.2 g/cm³; and alternatively, within therange of about 0.1 to about 0.18 g/cm³. Additional informationconcerning foam materials that may be used to form part of the midsole130 may be found in U.S. Pat. No. 7,941,938, the entire contents ofwhich are hereby incorporated by reference.

When desirable, the article of footwear 100 or shoe 100 may also includea platform upon which the foot will rest that separates the upper 110from the soles (outsole 120 and midsole 130). This platform is typicallya separate removable board called an insole (not shown) that is made ofcellulose or other materials, such as thermoplastic or thermosetelastomers, capable of providing a cushion between the outsole 120 ormidsole 130, when present, and the foot of the person wearing the shoe100. The insole may be treated with additives to inhibit bacterialgrowth

Referring once again to FIGS. 2C and 2D, the sole structure (outsole 120with or without a midsole 130) of the shoe 100 may be engaged with orattached to the upper 110 in any desired manner, including manners thatare conventionally known or used in the construction of footwear 100,such as through the use of cements or adhesives, by mechanicalconnectors, and by sewing or stitching, to name a few. In theillustrated example shown in FIGS. 2A and 2B, the sole structureincludes both a midsole component 130 and an outsole component 120engaged with or attached to the midsole component 130. This engagementmay be accomplished in any desired manner, including manners that areconventionally known or used in the construction of footwear 100 (e.g.,by cements or adhesives, by mechanical connectors, by sewing orstitching, etc.) as previously mentioned or by a bond formed directlybetween the upper 110 and outsole 120 via a UV radiation cure mechanism.

Referring now to FIG. 3A, a method of forming an article of footwear,apparel, or sporting equipment is provided. This method 200 generallycomprises attaching 215 a first component formed by the molding processof FIG. 1 as described above and as further defined herein 220; and asecond component 230, thereby forming the article. When desirable, thefirst component formed by the molding process may be an outsole 225 andthe second component may be an upper 210 with the resulting footwearbeing with or without a midsole or midsole component. When the midsoleis present, the method may further comprise attaching the midsole ormidsole component to the outsole before or concurrently with theattaching of the upper to the outsole 232.

The attachment of the upper to the outsole or the midsole to the outsole230 may comprise heating the outsole or midsole to a temperature fromabout 40° C. up to about 170° C. in order to soften the UV radiationcurable material and/or exposing the outsole to ultraviolet (UV)radiation 235 in an amount and for a duration that is sufficient to atleast partially cure the UV radiation curable material. Alternatively,the amount of and/or duration of UV exposure is sufficient to fully curethe UV radiation curable material. Typically, the UV radiation curablematerial is cooled below its softening temperature after or prior tobeing exposed to the ultraviolet (UV) radiation. In other words, thestep of contouring and/or adhering the UV radiation curable material maybe performed as the temperature of the UV radiation curable material isincreased to a temperature at which the material softens, followed bydecreasing the temperature of the UV radiation curable material below asoftening point, with the decrease in the temperature occurring beforeor after the UV curing has been accomplished.

Referring now to FIG. 3B, the strength of the attachment between thevarious components within the shoe may further be enhanced by applyingan adhesive, a primer, or a combination thereof to a surface the midsoleor midsole components 234, or to one or more of the outsole, or upper213. Another means of enhancing the adhesion between the variouscomponents within the shoe is to apply a texture to at least one surfaceof the outsole 217 and/or to the midsole 236, when present, such thatthe attachment of the outsole to the upper and/or the attachment of theoutsole to the midsole exhibits an increase in bond strength as comparedto the same attachment made without the surface texture being present.The strength of the attachment of the outsole to the upper and theattachment of the outsole to the midsole, when present, is such that theattachments exhibits a bond strength that is maintained after exposureto a force greater than or equal to 2.5 kgf/cm; alternatively, afterexposure to a force of about 3.0 kgf/cm or greater as measured accordingto the Bonding Strength Testing Protocol.

The adhesive may include, but not be limited to epoxy adhesives,urethane adhesives, acrylic adhesives, cyanoacrylate adhesives, siliconeadhesives, modified silane polymers, hot melt adhesives, contact glue(e.g., solvent-borne adhesive comprising natural or synthetic rubberresins with or without halogenation, such as polychloroprene, etc.) orcombinations thereof. Alternatively, the adhesive is a thermoplasticpolyurethane (TPU), cyanoacrylate, an acrylic, a contact adhesive, asilicone a modified silane polymer, or a mixture thereof.

A primer is a preparatory coating applied to the surface of a material(e.g., 1^(st) surface) prior to adhesion to another material (e.g.,2^(nd) surface) with or without an adhesive. A primer ensures betteradhesion of primed 1^(st) surface to the 2^(nd) surface, increases thedurability of the bond between the 1^(st) and 2^(nd) surfaces, andprovides additional protection for the material (1^(st) surface) towhich the primer was applied. The primer may include, withoutlimitation, pre-polymer solutions or dispersions of epoxies, urethanes,acrylics, cyanoacrylates, silicones, and combinations thereof.

The UV radiation curable material incorporated as at least a portion ofthe component, such as an outsole, for example, may be an UV radiationcurable elastomer as previously described above and further definedherein. Alternatively, the UV radiation curable material is an UVradiation curable polyurethane rubber. The UV radiation curable mayfurther comprise a vulcanized rubber, such as a nitrile rubber or thelike. The UV radiation curable material comprise a thermoset or athermoplastic polymer, including but not limited to a polyurethane.

Referring now to FIG. 3C, the method 200 may further comprise as part ofthe molding process a mold surface, wherein at least a portion of themolding surface imparts a pattern to at least one surface of the outsole223. When desirable this pattern may be a tread pattern. The method 200may also include a cooling step in which the outsole is cooled prior tobeing removed from the molding surface 227.

Referring now to FIG. 4A, another method of forming an article offootwear, apparel, or sporting equipment is provided. This method 300generally comprises receiving a first component comprising an UVradiation curable material 320; receiving a second component 310; andattaching the second component to the first component 330. The methodmay also further comprise exposing the component to UV radiation 335,such that the UV radiation curable material is at least partially cured;alternatively, fully cured. When the article is an article of footwear,the first component may be an outsole 321 and the second component maybe an upper 311.

Referring now to FIG. 4B, an adhesive, a primer, or both may optionallybe applied 313 to one or more of the upper and the component in order toenhance adhesion there between. In addition, a texture may be applied317 to the upper, the component, or a combination thereof. This texturemay be a tread pattern when and if desired. Optionally, the componentmay be a molded component 323 and when desirable, this molded componentmay be an outsole 325.

Referring now to FIG. 5, a method of finishing an article of footwear,apparel, or sporting equipment is provided. This method 400 generallycomprises providing an article having a first component and secondcomponent as previously defined herein 405 (best shown in FIGS. 2A-2D)and exposing the first component to ultraviolet (UV) radiation, suchthat the first component is fully cured 410. When the article is anarticle of footwear, the first component may be an outsole and thesecond component may be an upper 415. In this case, the finishing of thearticle of footwear exposes the outsole to UV radiation, such that theoutsole is fully cured 410. Other finishing operations, as previouslydescribed above may also be performed upon the shoe without exceedingthe scope of the present disclosure.

The following specific examples are given to illustrate the attachmentbetween the molded component and other parts of the article of apparelor sporting equipment, such as garments and footwear, formed accordingto the teachings of the present disclosure, as well as the bond strengthformed there between, and should not be construed to limit the scope ofthe disclosure. Those skilled-in-the-art, in light of the presentdisclosure, will appreciate that many changes can be made in thespecific embodiments which are disclosed herein and still obtain alikeor similar result without departing from or exceeding the spirit orscope of the disclosure. One skilled in the art will further understandthat any properties reported herein represent properties that areroutinely measured and can be obtained by multiple different methods.The methods described herein represent one such method and other methodsmay be utilized without exceeding the scope of the present disclosure.

Bond Strength Testing Protocol

A bonding test is performed with the purpose of evaluating the strengthof the adhesion bond along an interface of the UV radiation curedmaterial and another material. For example, the adhesion bond can be abond between an outsole and an upper. In this test a flat component(e.g., a textile) is placed in contact with an UV radiation curablematerial on a flat surface, and then a compressive force of at least 2kgf/cm² is applied to the combination of the component and the UVradiation curable material, leaving an edge region of the component andan opposing edge region of the UV radiation curable material which arenot in contact or compressed. Following the compression, the combinationof the component and the UV radiation curable material is then exposedUV radiation in an amount and for a duration that is sufficient to fullycure the UV radiation curable material, forming a composite sheetincluding the edge regions. The composite sheet is then cut into stripsto form test specimens, with each test specimen including a length ofthe edge regions for grasping in a test apparatus capable of measuringapplied force, such as an Instron testing system. Each strip has a widthof 25.4 cm (1 inch). Intervals are marked along the length of the stripswith each interval being spaced apart by 2 cm. Depending upon the lengthof the strips, between 2 and 5 intervals may be marked on each strip.The edge of textile and the UV radiation curable material of a moldedspecimen are then grasped at an edge region by the testing apparatus.The tabs are then pulled with an increasing amount of force until thesurfaces of the textile and the UV radiation curable material areseparated over the length of at least one interval. The amount of forcerequired to separate the surfaces of the textile and the UV radiationcurable material is measured by the testing apparatus. In order for aspecimen to be considered as passing the bonding test, a minimum forceof 2.5 kgf/cm force is required to separate the bonded surfaces of thecomponent and the UV radiation cured material.

EXAMPLE 1 Bonding Performance

UV radiation curable polyurethane rubber (Millathane® UV, TSE IndustriesInc., Clearwater, Fla.) was attached using a compression molding processto a knit textile formed of TPU coated yarn (Runs A & B) manufactured bySambu Fine Chemicals, Korea and to a knit textile formed of uncoated PETyarn (Runs C & D) manufactured by Unifi, Inc. (Greensboro, N.C., USA).The combinations of the UV radiation curable polyurethane rubber andknit textiles were then exposed to UV light, fully curing the UVradiation curable polyurethane rubber. Each of the four cured sampleswas prepared and tested twice (Tests 1 & 2) according to the BondStrength Testing Protocol described above. The measured test results aresummarized in Table 1.

TABLE 1 Bonding Test Results Run Test 1 Test 2 Pass/Fail No. Description(kgf/cm) (kgf/cm) (≥2.5 kgf/cm) A UV radiation curable 3.4 3.4 PASScured polyurethane rubber w/TPU coated yarn B UV radiation curable 3.43.8 PASS cured polyurethane rubber w/TPU coated yarn C UV radiationcurable Tab Tab PASS cured polyurethane broke at broke at rubberw/uncoated PET 2.9 2.9 yarn D UV radiation curable 3.1 3.5 PASS curedpolyurethane rubber w/uncoated PET yarn

This example demonstrates that the UV radiation curable polyurethanerubber can be attached to a textile with the bond strength necessary tobe used as an outsole in an article of footwear. More specifically, RunsA-D maintained their bond after application of a 2.5 kgf/cm force in theBond Strength Test, and more than a 2.9 kgf/cm force was necessary tobreak the bonds.

Within this specification, embodiments have been described in a waywhich enables a clear and concise specification to be written, but it isintended and will be appreciated that embodiments may be variouslycombined or separated without parting from the invention. For example,it will be appreciated that all preferred features described herein areapplicable to all aspects of the invention described herein.

The subject matter of the disclosure may also relate, among others, tothe following aspects:

1. A method of forming a component of an article of apparel or sportingequipment, the method comprising:

placing an ultraviolet (UV) radiation curable material in contact with amolding surface;

conforming the UV radiation curable material to a shape of the moldingsurface, forming a molded component; and

removing the molded component from the molding surface, such that thecomponent maintains the shape of the molding surface.

2. The method of Aspect 1, wherein the method further comprisesincreasing a temperature of at least a portion of the UV radiationcurable material before the placing, before the conforming, or duringthe conforming.

3. The method of Aspect 1 or 2, wherein the method further comprisesapplying compressive force to the molding surface or to the UV radiationcurable material during the conforming.

4. The method of Aspect 3, wherein applying the compressive forceincludes applying increased pressure or applying a vacuum.

5. The method of any of Aspects 1 to 4, wherein the method comprisesprotecting the UV radiation curable material from ultraviolet (UV)radiation during one or more steps of the method.

6. The method of any of Aspects 1 to 5, wherein during the conformingstep, the UV radiation curable material is maintained at a temperaturebelow 170 degrees Celsius.

7. The method of any of Aspects 1 to 6, wherein the molding surface ispart of a compression mold.

8. The method of any of Aspects 1 to 6, wherein the molding surface is asingle substantially planar molding surface.

9. The method of any of Aspects, 1 to 8, where the molding surface istextured.

10. The method of any of Aspects 1 to 9, wherein the method furthercomprises forming the UV radiation curable material into a sheet beforethe conforming.

11. The method of any of Aspects 1 to 10, wherein the method furthercomprises cutting or trimming the UV radiation curable material beforethe conforming.

12. The method of any of Aspects 1 to 11, wherein the method furthercomprises cutting or trimming UV radiation curable material from themolded component.

13. The method of any of Aspects 1 to 12, further comprising exposingthe molded component to ultraviolet radiation in an amount and for aduration that is sufficient to partially cure the UV radiation curablematerial.

14. The method of any of Aspects 1 to 12, further comprising exposingthe molded component to ultraviolet radiation in an amount and for aduration that is sufficient to fully cure the UV radiation curablematerial.

15. The method of any of Aspects 1 to 14, wherein the component of thearticle of apparel or sporting equipment is a component of a garment.

16. The method of any of Aspects 1 to 14, wherein the component of thearticle of apparel or sporting equipment is a component of an article ofsporting equipment.

17. The method of any of Aspects 1 to 14, wherein the component of thearticle of apparel or sporting equipment is a component of an article offootwear.

18. The method of Aspect 17, wherein the component of the article offootwear is an outsole.

19. The method of any of Aspects 1 to 18, wherein the UV radiationcurable material includes an UV radiation curable elastomer.

20. The method of any of Aspects 1 to 19, wherein the UV radiationcurable material includes a rubber.

21. The method of any of Aspects 1 to 20, wherein the UV radiationcurable material includes an UV radiation curable polyurethane rubber.

22. The method of any of Aspects 1 to 20, wherein the UV radiationcurable material includes an UV radiation curable millable polyurethanegum.

23. The method of any of Aspects 1 to 22 wherein the UV radiationcurable material further comprises one or more photoinitiators.

24. The method of Aspect 23, wherein the photoinitiators areindependently selected from the group consisting of phosphine oxides,benzophenones, a-hydroxy-alkyl aryl ketones, thioxanthones,anthraquinones, acetophenones, benzoins and benzoin ethers, ketals,imidazoles, phenylglyoxylic acids, peroxides, and sulfur-containingcompounds.

25. The method of any of Aspects 1 to 24, wherein the UV radiationcurable material further comprises one or more processing aids.

26. The method of Aspect 25, wherein the processing aids areindependently selected from the group of plasticizers, mold releaseagents, lubricants, antioxidants, flame retardants, dyes, pigments,reinforcing and non-reinforcing fillers, fiber reinforcements, and lightstabilizers.

27. The method of any of Aspects 1 to 26, wherein at least a portion ofthe molding surface in the molding process imparts a pattern to at leastone surface of the molded component.

28. The method of any of Aspects 1 to 27, wherein the method furthercomprises a cooling step after the application of the compressive force,and prior to removing the molded component from the mold.

29. A method of forming an article of footwear, apparel or sportingequipment, the method comprising:

attaching a first component of an article of footwear, apparel orsporting equipment formed according to the molding process of any ofAspects 1 to 18, and a second component, thereby forming the article offootwear, apparel or sporting equipment.

30. The method of Aspect 29, wherein the first component is an outsole.

31. The method of Aspect 30, wherein the second component is an upperfor an article of footwear.

32. The method of Aspect 31, wherein the method further comprisesattaching a midsole or midsole component and the outsole before orconcurrently with attaching the upper and the outsole.

33. The method of Aspect 32, wherein the attaching of the upper and theoutsole or the upper and the midsole and the outsole comprises exposingthe outsole to ultraviolet radiation in an amount and for a durationsufficient to at least partially cure the UV radiation curable material.

34. The method of Aspect 32, wherein the attaching the upper to theoutsole or the midsole to the outsole comprises exposing the outsole toultraviolet radiation in an amount and for a duration sufficient tofully cure the UV radiation curable material.

35. The method of any of Aspects 30 to 34, wherein at least one surfaceof the outsole includes a pattern.

36. The method of Aspect 35, wherein the pattern is a tread pattern.

37. The method of any of Aspects 31 to 36, wherein the upper comprisesone or more of a textile, leather, or both.

38. The method of Aspect 37, wherein the textile includes a knittextile, a woven textile, a non-woven textile, a braided textile, or anycombination thereof.

39. The method of any of Aspects 37 or 38, wherein the textile includesone or more natural or synthetic fibers or yarns.

40. The method of Aspect 39, wherein the synthetic yarns comprise athermoplastic polyurethane (TPU), a polyamide, a polyester, apolyolefin, or a mixture thereof.

41. The method of any of Aspects 31 to 40, wherein the method furthercomprises applying an adhesive, a primer, or a combination thereof to asurface of one or more of the outsole or the upper.

42. The method of any of Aspects 31 to 41, wherein at least one surfaceof the outsole is textured, such that the attachment of the outsole tothe upper exhibits an increase in bond strength as compared to the sameattachment made without the texture.

43. The method of any of Aspects 32 or 34, wherein the method furthercomprises applying an adhesive, a primer, or a combination thereof to asurface of the midsole.

44. The method of Aspect 43, wherein the adhesive comprises athermoplastic polyurethane (TPU), a cyanoacrylate, an acrylic, a contactadhesive, a silicone a modified silane polymer, or a mixture thereof.

45. The method of Aspect 43 wherein the primer comprises a pre-polymersolution or dispersion of an epoxy, urethane, acrylic, cyanoacrylate,silicone, or a combination thereof.

46. The method of Aspect 32, wherein the midsole comprises a foammaterial formed as sheet stock, by injection molding, by compressionmolding, or a combination thereof.

47. The method of Aspect 46, wherein the foam material comprises apolyurethane (PU), an ethylene vinyl acetate (EVA), or a mixture of PUor EVA with a rubber.

48. The method of any of Aspects 32 to 34 or 43 to 47, wherein at leastone surface of the midsole is textured, such that the attachment of theoutsole to the midsole exhibits an increase in bond strength as comparedto the same attachment made without the texture.

49. The method of any of Aspects 31 to 48, wherein the attachment of theoutsole to the upper exhibits a bond strength that is maintained afterexposure at a force of 2.5 kgf/cm or greater as measured according tothe Bond Strength Testing Protocol.

50. An article of footwear, apparel, or sporting equipment, the articleof footwear, apparel, or sporting equipment being formed according tothe method of any of Aspects 29-49.

51. An article of apparel or sporting equipment comprising:

a first molded component of an article of apparel or sporting equipmentcomprising an ultraviolet (UV) radiation cured material; and

a second component of an article of apparel or sporting equipment,wherein the first and second components are attached to each other andform the article of apparel or sporting equipment.

52. The article of Aspect 52, wherein the first component and the secondcomponent are attached to each other at least by a bond formed directlybetween the UV radiation cured material of the first component and thesecond component.

53. The article of Aspect 53, wherein an interface between the UVradiation cured material of the first component and the second componentis free of adhesive materials.

54. The article of any of Aspects 52 to 54, wherein the article ofapparel is an article of footwear.

55. The article of Aspect 55, wherein the first component is an outsolefor an article of footwear.

56. The article of any of Aspects 51 to 55, wherein the UV radiationcured material includes an UV radiation curable elastomer.

57. The article any of Aspects 51 to 56, wherein the UV radiation curedmaterial includes a rubber.

58. The article of any of Aspects 51 to 57, wherein the UV radiationcured material includes an UV radiation cured polyurethane rubber.

59. The article of any of Aspects 51 to 58, wherein at least one surfaceof the first molded component includes a pattern.

60. The article of any of Aspects 51 to 59, wherein the first moldedcomponent further comprises one or more processing aids.

61. The article of Aspect 60, wherein the processing aids areindependently selected from the group of plasticizers, mold releaseagents, lubricants, antioxidants, flame retardants, dyes, pigments,reinforcing and non-reinforcing fillers, fiber reinforcements, and lightstabilizers.

62. The article of any of Aspect 51 to 61, wherein the second componentcomprises one or more of a textile, leather, or both.

63. The article of Aspect 62, wherein the textile includes a knittextile, a woven textile, a non-woven textile, a braided textile, or anycombination thereof.

64. The article of any of Aspects 62 or 63, wherein the textile includesone or more natural or synthetic fibers or yarns.

65. The article of Aspect 64, wherein the synthetic yarns comprise athermoplastic polyurethane (TPU), a polyamide, a polyester, apolyolefin, or a mixture thereof.

66. The article of any of Aspects 51 to 65, wherein at least one surfaceof the first molded component is textured, such that the attachment ofthe first molded component to the 2^(nd) component exhibits an increasein bond strength as compared to the same attachment made without thetexture.

67. The article of any of Aspects 51 to 66, wherein the attachment ofthe first component to the second component exhibits a bond strengththat is greater than or equal to 2.5 kgf/cm as measured according to theBond Strength Testing Protocol.

68. An article of footwear, apparel, or sporting equipment comprising:

a first component having a predetermined shape; the first componentcomprising an UV radiation curable material in an uncured or partiallycured state; and

a second component; the second component being attached to the firstcomponent.

69. The article of Aspect 68, wherein the article of apparel is anarticle of footwear in which the first component is an outsole and thesecond component is an upper.

70. The article of Aspect 69, wherein the article of footwear furthercomprises a midsole or a midsole component attached to the outsole.

71. The article of any of Aspects 69 to 70, wherein the UV radiationcurable material comprises an UV radiation curable elastomer.

72. The article of any of Aspects 69 to 71, wherein the UV radiationcurable material further comprises one or more photoinitiators and/orother processing aids.

73. The article of any of Aspects 69 to 72, wherein at least one surfaceof the outsole has a tread pattern.

74. The article of any of Aspects 69 to 73, wherein the upper comprisesone or more of a textile, leather, or both.

75. The article of Aspect 70, wherein the midsole comprises a foammaterial formed as sheet stock, by injection molding, or by compressionmolding.

76. The article of Aspect 75, wherein the foam material comprises apolyurethane (PU), an ethylene vinyl acetate (EVA), a rubber, or acombination thereof.

77. The article of any of Aspects 69-76, wherein the article of footwearfurther comprises an adhesive, a primer, or a combination thereoflocated on a surface of one or more of the outsole or the upper.

78. The article of any of Aspects 69-77, wherein at least one surface ofthe outsole is textured, such that the attachment of the outsole to theupper exhibits an increase in bond strength as compared to the sameattachment made without the texture.

79. The article of any of Aspects 70, 75, or 76, wherein the article offootwear further comprises an adhesive, a primer, or a combinationthereof located on a surface of the midsole.

80. The article of any of Aspects 70, 75, or 76, wherein at least onesurface of the midsole is textured, such that the attachment of theoutsole to the midsole exhibits an increase in bond strength as comparedto the same attachment made without the texture.

81. The article of any of Aspects 69 to 80, wherein the attachment ofthe outsole to the midsole exhibits a bond strength that is maintainedafter exposure up to a force of 2.5 kgf/cm as measured according to theBond Strength Testing Protocol.

82. A method of forming an article of footwear, apparel, or sportingequipment, the method comprising:

receiving a first component comprising an ultraviolet (UV) radiationcurable material;

receiving a second component; and

attaching the second component to the first component.

83. The method of Aspect 82, wherein the first component in the articleof footwear is an outsole and the second component is an upper.

84. The method of Aspect 83, wherein the method further comprisesattaching a midsole or midsole component and the outsole before orconcurrently with attaching the upper and the outsole.

85. The method of Aspect 84, wherein the attaching of the upper and theoutsole or the upper and the midsole and the outsole comprises exposingthe outsole to ultraviolet (UV) radiation in an amount and for aduration sufficient to at least partially cure the UV radiation curablematerial.

86. The method of Aspect 84, wherein the attaching the upper to theoutsole or the midsole to the outsole comprises exposing the outsole toultraviolet (UV) radiation in an amount and for a duration sufficient tofully cure the UV radiation curable material.

87. The method of any of Aspects 83 to 86, wherein at least one surfaceof the outsole includes a pattern.

88. The method of Aspect 87, wherein the pattern is a tread pattern.

89. The method of any of Aspects 83 to 88, wherein the upper comprisesone or more of a textile, leather, or both.

90. The method of Aspect 89, wherein the textile includes a knittextile, a woven textile, a non-woven textile, a braided textile, or anycombination thereof.

91. The method of any of Aspects 89 or 90, wherein the textile includesone or more natural or synthetic fibers or yarns.

92. The method of Aspect 91, wherein the synthetic yarns comprise athermoplastic polyurethane (TPU), a polyamide, a polyester, apolyolefin, or a mixture thereof.

93. The method of any of Aspects 83 to 92, wherein the method furthercomprises applying an adhesive, a primer, or a combination thereof to asurface of one or more of the outsole or the upper.

94. The method of any of Aspects 83 to 93, wherein at least one surfaceof the outsole is textured, such that the attachment of the outsole tothe upper exhibits an increase in bond strength as compared to the sameattachment made without the texture.

95. The method of any of Aspects 84 to 86, wherein the method furthercomprises applying an adhesive, a primer, or a combination thereof to asurface of the midsole.

96. The method of Aspect 95, wherein the adhesive comprises athermoplastic polyurethane (TPU), a cyanoacrylate, an acrylic, a contactadhesive, a silicone a modified silane polymer, or a mixture thereof.

97. The method of Aspect 95 wherein the primer comprises a pre-polymersolution or dispersion of an epoxy, urethane, acrylic, cyanoacrylate,silicone, or a combination thereof.

98. The method of Aspect 84, wherein the midsole comprises a foammaterial formed as sheet stock, by injection molding, by compressionmolding, or a combination thereof.

99. The method of Aspect 98, wherein the foam material comprises apolyurethane (PU), an ethylene vinyl acetate (EVA), or a mixture of PUor EVA with a rubber.

100. The method of any of Aspects 84 to 86, 98 or 99, wherein at leastone surface of the midsole is textured, such that the attachment of theoutsole to the midsole exhibits an increase in bond strength as comparedto the same attachment made without the texture.

101. The method of any of Aspects 83 to 100, wherein the attachment ofthe outsole to the upper exhibits a bond strength that is maintainedafter exposure at a force of 2.5 kgf/cm or greater as measured accordingto the Bond Strength Testing Protocol.

102. A method of finishing an article of footwear, apparel, or sportingequipment; the method comprising:

providing the article of any of Aspects 68 to 81, which includes a firstcomponent and a second component; and

exposing the first component to ultraviolet (UV) radiation, such thatthe first component is fully cured.

103. The method of Aspect 102, wherein the article is the article offootwear of any of Aspects 69 to 81 in which the first component is anoutsole and the second component is an upper.

104. The method of any of Aspects 102 or 103, wherein the UV irradiationresults from an UV light that transmits a wavelength of light that isthe same as the excitation wavelength exhibited by a photoinitiatorpresent in the first component.

105. The method of Aspect 104, wherein the wavelength transmitted by theUV light is in the range of about 180 nm to about 400 nm.

The foregoing description of various forms of the invention has beenpresented for purposes of illustration and description. It is notintended to be exhaustive or to limit the invention to the precise formsdisclosed. Numerous modifications or variations are possible in light ofthe above teachings. The forms discussed were chosen and described toprovide the best illustration of the principles of the invention and itspractical application to thereby enable one of ordinary skill in the artto utilize the invention in various forms and with various modificationsas are suited to the particular use contemplated. All such modificationsand variations are within the scope of the invention as determined bythe appended claims when interpreted in accordance with the breadth towhich they are fairly, legally, and equitably entitled.

What is claimed is:
 1. An article of sporting equipment, the article comprising: a first molded component of an article of sporting equipment, the first molded component comprising an ultraviolet (UV) radiation cured material, wherein the UV radiation cured material comprises a millable UV polyurethane gum; and a second component of an article of sporting equipment, wherein the first molded component and the second component are attached to each other and form the article of sporting equipment, wherein the first molded component and the second component are attached to each other at least by a bond formed directly between the UV radiation cured material of the first molded component and a material of the second component; and wherein the bond formed directly between the UV radiation cured material of the first molded component and the material of the second component exhibits a bond strength greater than or equal to 2.5 kgf/cm as measured according to the Bond Strength Testing Protocol.
 2. The article of claim 1, wherein the bond between the UV radiation cured material of the first molded component and the second component is free of adhesive materials.
 3. The article of claim 1, wherein the second component comprises one or more of a textile, or a leather, or both.
 4. The article of claim 1, wherein at least one surface of the first molded component includes a pattern.
 5. The article of claim 1, wherein the second component comprises the textile.
 6. The article of claim 5, wherein the textile includes a knit textile, a woven textile, a non-woven textile, a braided textile, or any combination thereof
 7. The article of claim 5, wherein the textile includes one or more natural or synthetic fibers or yarns.
 8. The article of claim 5, wherein the textile includes synthetic yarns and the synthetic yarns comprise a thermoplastic polyurethane (TPU), a polyamide, a polyester, a polyolefin, or a mixture thereof.
 9. The article of claim 1, wherein at least one surface of the first molded component is textured, such that the bond strength of the bond between the first molded component and the second component exhibits an increase as compared to the same bond made without the texture. 